Apparatus and method for consolidation welding

Abstract

The present application discloses an apparatus for consolidation welding of an electrical conductor, in particular to an electrical terminal, preferably for resistance-monitored circuitry in a motor vehicle, having a bottom welding tool, on which a conductor section to be consolidated can be arranged, as well as three movable welding tools, whereby with a movable welding tool, which has two translational degrees of freedom, a width of the conductor section to be consolidated can be variably adjusted with reference to the bottom welding tool, and the other two movable welding tools can be moved in such a way that they seal off a compression chamber delimited by the width of the conductor section to be consolidated in a direction of its perimeter.

1 - 14 . (canceled) 
     
     
         15 . Apparatus for consolidation welding of an electrical conductor, in particular to an electrical terminal, preferably for resistance-monitored circuitry in a motor vehicle, comprising:
 a bottom welding tool, on which a conductor section to be consolidated can be arranged, as well as three movable welding tools, whereby with a movable welding tool, which has two translational degrees of freedom, a width of the conductor section to be consolidated can be variably adjusted with reference to the bottom welding tool, and   the other two movable welding tools can be moved in such a way that they seal off a compression chamber delimited by the width of the conductor section to be consolidated in a direction of its perimeter.   
     
     
         16 . Apparatus according to  claim 15 , wherein on the bottom welding tool, an electrical terminal can be provided, and on its electrical connection zone the section to be consolidated of the electrical conductor can be arranged, and
 by means of the three movable welding tools, the compression chamber is formed on the connection zone of the terminal.   
     
     
         17 . Apparatus according to  claim 15 , wherein the bottom welding tool and one of the other welding tools are combined into a bottom tool, and the two remaining welding tools are combined into a top tool, and wherein
 one welding tool is arranged in the top tool and in the bottom tool opposite the respective other welding tool in the top tool and in the bottom tool, preferably vertically movable and preferably directly adjacent to it.   
     
     
         18 . Apparatus according to  claim 15 , wherein the welding tool of the top tool and of the bottom tool is a welding jaw, preferably a ceramic jaw; and
 the welding tool of the top tool and of the bottom tool is a welding device, preferably an electrode.   
     
     
         19 . Apparatus according to  claim 15 , wherein the top tool is provided on/in a holder, and the welding jaw of the top tool is provided elastically on/in the holder, and/or
 the bottom tool is provided on/in a holder, and the welding jaw of the bottom tool is provided elastically on/in the holder.   
     
     
         20 . Apparatus according to  claim 15 , wherein the holder of the top tool is movable in two planes, preferably vertical and horizontal. 
     
     
         21 . Apparatus according to  claim 15 , wherein preferably both welding devices are of wider form than the electrical terminal in a section to be welded, or the width of the section to be consolidated of the electrical conductor. 
     
     
         22 . Apparatus according to  claim 15 , wherein the apparatus is a resistance welding apparatus. 
     
     
         23 . Method for consolidation welding of an electrical conductor, in particular to an electrical terminal, preferably for resistance-monitored circuitry in a motor vehicle, wherein
 on a bottom tool, a conductor section to be consolidated is positioned, and a compression chamber of variable width is formed around the conductor section to be consolidated by the bottom tool and a top tool, and   next, a consolidation welding method is carried out by the bottom tool and top tool, the conductor section to be consolidated being consolidated and welded.   
     
     
         24 . Method according to  claim 23 , wherein before the positioning of the section to be consolidated of the electrical conductor, an electrical terminal is provided on the bottom tool, and
 after that, the conductor section to be consolidated is positioned on an electrical connection zone of the terminal, and   next, the top tool is partly placed on the connection zone, in such a way that the width of compression chamber is restricted to the terminal.   
     
     
         25 . Method according to  claim 23 , wherein before or during the execution of the consolidation welding method, an insulation crimp of the electrical terminal with an electrical cable is produced by a crimping tool. 
     
     
         26 . Method according to  claim 23 , wherein the top tool includes a welding device and a welding jaw, and the width of the compression chamber for the section to be consolidated of the electrical conductor is limited by the welding jaw, and/or
 the bottom tool includes a welding device and a welding jaw, and the width of the compression chamber for the section to be consolidated of the electrical conductor is limited by the welding jaw.   
     
     
         27 . Method according to  claim 23 , wherein the welding jaws of the top tool and of the bottom tool are elastically movable relative to the welding device of the top tool and of the bottom tool respectively, and the top tool is moved in two planes, in such a way that
 in the formation of the compression chamber, the welding jaw of the top tool is displaced relative to the welding device of the top tool, and the welding jaw of the bottom tool is displaced relative to the welding device of the bottom tool.   
     
     
         28 . Method according to  claim 23 , wherein the welding process is a resistance welding process.